I have seen similar questions regarding this issue, but this seems a little odd. Whenever a Boolean Modifier is used between two components, everything disappears. Although whenever I scale both components down half the size, the modifier works perfectly normal. The union turns out exactly as anticipated, which I could then scale back up to the normal size. Having to do this work around seems a little odd, since its telling me there are no issues with the geometry of the components.
I did complete a basic list of checks on the components before any boolean modifier is used in order to limit any issues that may occur:
- Applied any scaling translations on the components
- Removed any doubles
- Recalculated all the normals making sure each is facing outward
- Verified components are manifold to the best of my knowledge
Is it possible, due to a larger volume being taken up, that blender ended up running out of memory while executing the modifier? This would make sense since the values used during the calculations would end up larger based on the coordinates each point has (everything is farther apart). Any thoughts?
I should note that 4GB of RAM is available and I'm currently working with version 2.75 of Blender. I have also attached the .blend file of the two components I am trying to merge together for anyone who feels the need to try the union on their system.